Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures 460
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Electron beam freeform fabrication (EBF3) parts exhibit a ridged surface finish typical of many layer-additive processes. Thus, post-processing is required to produce a net shape with a smooth surface finish. High speed milling, wire electrical discharge machining (EDM), electron beam glazing, and glass bead blasting were performed on EBF3-built 2219 aluminum alloy parts to reduce or eliminate the ridged surface features. Surface roughness, surface residual stress state, and microstructural characteristics were examined for each of the different surface treatments to assess the quality and effect of the surface treatments on the underlying material. The analysis evaluated the effectiveness of the different surface finishing techniques for achieving a smooth surface finish on an electron beam freeform fabricated part.